Kv Farell Pha Study Enhancement
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Transcript of Kv Farell Pha Study Enhancement
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Process Hazard Analysis: Study Enhancement
Keith V. Farrell, MS ChE
PSM Coordinator
INVISTA, Orange Plant
10/27/2009 1
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Beginning Thoughts
The Three Laws of TechnologyThe Three Laws of Technology
By Arthur C. Clark
• When an engineer states that something is possible, he is almost certainly RIGHT. When he states that something is impossible, he is very probably WRONG.
• Any sufficiently advanced technology is indistinguishable from magic.
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Study Objectives
• Federal Requirements
• Companies Requirements
• Tools
• Training
• “Bringing all Together”
• Cost and Savings
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Federal Requirements
• OSHA CFR Title 29 §1910.119
– Process Safety Management of Highly Hazardous Chemicals
• EPA CFR Title 40 Part 68
– Chemical Accident Prevention Provisions
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Company Requirements
• Accuracy and Precision
• Compliance
• Speed
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Accuracy and Precision
• Right Recommendations
• Vague Recommendations
• Constrictive Recommendations
• Wrong Recommendations
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Speed
• TIME IS MONEY!!!!
• Too Quick of a Pace for the Study
– Team Fails by Being Rushed
– Missed Consequences
• Too Slow of a Pace for the Study
– Team Fails by Tiring of Thinking
– Missed Consequences
– Unnecessary Consequences (Whines)
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Tools
• Willing People
• Deep Knowledge
• Accessible Information
• Archiving and Accessing Captured Information for Study
• Equipment
• EIS
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Tools
• People, Knowledge, Information, Computer Programs, Archiving Information, Access to Information
• Typical for All PHAs
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Tools: Equipment
• Displaying Information
– Eye strain
– Comfort
• Markups of P&IDs
– To Keep the Team on Same “Page”
– Verbal Directions of Nodes
– Not Quick
• Derailing the Thought Train
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Tools: Equipment, cont.
•Monitors for each Team Member & Space remaining for P&IDs
– Same Page Issue
– Quick Editing
– Comfortable
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Tools: Equipment, cont.
•Document Camera to Project Drawings
– Use Basic Marked Drawings
– Lower Eye Strain
– Faster Information Recognition
– Visual Data preferred
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EIS
Electronic Information Systems (EIS)
• What
• Where
• When
• How
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EIS: Defined.
• Databases
• Information Availability
• Benefits
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EIS: Databases
• PSI necessary for PHA
– PSI
– Alarms/ SIS
– SOLs
– PSV
– Process Control Points
– Process Information Points
– Procedures
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EIS
• Proper Form of Database
– Accessibility
– User Friendly
– Updateable
– Protectable
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WHAT FORM OF DATABASE?
• Software Needs Questions
– Stable
– Quick
– Ease of Use
– Expandable
– Software Life-span
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Accessibility and User Friendly
• Questions to ask
– Who needs access
– What level of access
– Any training necessary
– Who will fix problems
– Who will maintain information
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Expandable and Software Life-span
• What will be your PSI needs in the Future
• What software will be there at that time
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Cost Analysis
• Equipment
• Software
• Training for Leaders
• Savings!!!!!!!
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Equipment
• Seven Monitors @ $150 each
– Two – Operators
– Three– Engineers
– Two – Other Skill Sets
• One Document Camera @ $2000
• Other Minor Equipment @ $300
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Software
• PHA Software (Current)
• Adobe Writer @$650
(Based on the assumption you have a computer and associated operational software)
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Total Cost
• Equipment = $3350
• Software = $650
• Total = $3850
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Training for Leaders
Necessary Training
•Basic Leader Development (In House?)
•Basic Instructor Development (In House?)
•Negotiating Development (In House?)
Items to consider
•Basic Interview Development
•Basic Speakers Development
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Savings!!!!!!!
• Time for Initial Studies
– Normal; 5 to 8 weeks
– With Enhancements; 3 to 4 weeks
• Using one Operator & two Engineers; combined cost $270/hr
• Time Savings ~$11,300 per study
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Savings, cont.
• Time for Revalidation Studies
– Normal; 2 to 4 weeks
– Enhanced; 1 to 8 study days
• Using one Operator & two Engineers; combined cost $270/hr
• Time Savings ~ $11,300 for each study
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The Bottom Line
• Hardware and Software Total = $3350
• Savings per study = ~ $11,300
• Net Saving for the first Study = $7,450
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Last Comment
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DesiredDesiredResultsResults
PSIPSI
PH
AP
HA
Changes
Changes
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THANKS
•Mary Kay O’Connor Process Safety Center
•Dr. M. Sam Mannan
•INVISTAKeith V. Farrell
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A Few Questions????
Questions
Questions
Questions
Questions
Questions
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